5MW Battery Thermal Release Test System

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• This large heat release test system is developed with reference to ISO 9705, GB/T 20286-2006, GB/T 27904-2011, and GB/T 25207-2010 for large-scale battery fire heat release testing.
• The theory of measurement is based on oxygen-consumption calorimetry, where the heat released is proportional to the consumed oxygen and each kilogram of oxygen corresponds to 13.1 MJ/kg of heat.
• Measured parameters include heat release, ignition time, oxygen consumption rate, CO generation rate, CO2 generation rate, fuel gas flow, smoke density, and related combustion parameters.
• The system design refers to foreign studies and practical cases of 5 MW large-scale heat release systems, especially for duct layout, sampling positions, and stabilized flow sections.
• Built-in temperature sensors, gas flowmeters, gas samplers, and multi-stage filtered sampling pipelines help extend analyzer service life.
• The Windows-based Labview control system automatically acquires, analyzes, stores, and reports heat release rate, total heat release, and smoke density release data.

• The complete system includes the exhaust system, specimen fixtures, ignition system, smoke sampling and pretreatment system, gas analysis system, integrated control cabinet, and computer analysis system.

• The exhaust system consists of collection hood, guide duct, mixing duct, and test flue sections.
• Collection hood and exhaust duct material: SUS304 stainless steel.
• Collection hood plate thickness: not less than 2 mm.
• 1 MW conical stainless steel collection hood opening: 3000 mm x 3000 mm; height not less than 1000 mm.
• 5 MW conical stainless steel collection hood opening: 6000 mm x 9000 mm; height not less than 4000 mm.
• 1 MW exhaust duct diameter: not less than 400 mm.
• 5 MW exhaust duct diameter: not less than 1000 mm.
• 1 MW straight exhaust duct length: not less than 4000 mm, fitted with motorized air valve.
• 5 MW straight exhaust duct length: not less than 12000 mm, fitted with motorized air valve.
• Exhaust duct steel plate thickness: not less than 1.5 mm.
• 1 MW gas mixer size: not less than 900 mm x 900 mm x 900 mm.
• 5 MW gas mixer size: not less than 1800 mm x 1800 mm x 1800 mm.
• Gas mixers use internal double-layer baffles and withstand temperatures not less than 1100 °C.
• The flue test section includes smoke gas sampler, gas temperature measurement, airflow measurement, and photoelectric smoke density test system.
• A motorized air valve is installed at the exhaust outlet to prevent rainwater from entering the flue and is opened or closed automatically according to test status.
• The customer provides the infrastructure for pipeline installation according to actual site conditions.

• The system consists of fan, frequency inverter, airflow probe, differential pressure gauge, and thermocouples.
• Three-phase variable-frequency fans control airflow to ensure full collection of combustion smoke, with adjustable flow during testing.
• 1 MW fan airflow capacity: 12000 m3/h.
• 5 MW fan airflow capacity: 50000 m3/h.
• Taiwan Delta inverter is used for accurate duct velocity control.
• Bidirectional airflow probes are used for airflow pressure measurement.
• Imported U.S. differential pressure transmitter: range 0 to 2000 Pa, accuracy ±1% FS, hysteresis ±0.1% FS, maximum linear pressure 69 kPa, and 90% response time within 1 s.
• Imported OMEGA thermocouples monitor smoke temperature in real time with temperature accuracy of 0.1 °C and wire diameter less than 0.25 mm.
• 1 MW configuration uses one thermocouple, while 5 MW configuration uses four thermocouples.
• Air velocity signals are automatically calculated and fed back for closed-loop automatic control.

• The smoke sampling and pretreatment system includes sampler, filters, cold trap, suction pump, drying tube, and flow controller.
• The stainless sampler includes sampling holes facing opposite to the gas flow direction.
• A three-stage filtration system with 0.2 um filtration accuracy is used to protect the gas analyzers.
• The compressor-type cold trap is controlled at 0 to 5 °C and keeps the sampled gas at 4 ±1 °C.
• Imported suction pump: flow 33 L/min, vacuum degree 700 mmHg, pressure 2.5 bar.
• Drying tube removes water and impurities from sampled gas.
• Imported flow controller supplies stable sample gas flow to the analyzers.
• Smoke density light source: imported 0.5 W He-Ne laser.
• Imported photoelectric receiver: wavelength range 350 to 1100 nm, peak response 0.65 A/W, maximum output current 100 mA, gain adjustment 70 dB, linearity not less than 99.8%, instability less than 0.1%, and light receiving accuracy 0.1%.
• A one-touch five-level optical path auto-calibration system with imported Thorlabs standard filters is provided; deviation from theoretical values is controlled within 3%.
• A compensation photoelectric detection system is used to reduce interference caused by light source fluctuation.

• The combustion control system consists of gas piping, check valve, explosion-proof solenoid valve, mass flow controller, burner, and ignition controller.
• Stainless steel gas piping is used throughout the system.
• Sampling check valves, explosion-proof solenoid valves, and burner controllers with flame detection provide combustion safety.
• Mass flow controllers and sandbox burners are used for heat release step calibration.
• Ignition and gas flow can be controlled manually, while in calibration mode the system automatically controls ignition time and gas flow.
• A dedicated heat capacity test method is included according to UL 9540A clause 9.2.12, including specified temperature measuring point positions, number of points, and compensation calculations.

• Paramagnetic oxygen analyzer: O2 range 0 to 25%, linear deviation not greater than 0.5% of range, repeatability not greater than 50 ppm, and T90 below 3.5 s.
• Infrared CO and CO2 analyzer: CO range 0 to 1%, CO2 range 0 to 10%, linear deviation not greater than 1% of range, and T90 below 2.5 s.
• Total hydrocarbon analyzer uses flame ionization detection, range 0 to 10000 ppm, and T90 below 3 s.
• Palladium-nickel hydrogen analyzer: working range 0.4 to 5%, measurement accuracy 0.3%, and RS232 plus 4-20 mA outputs.
• The auxiliary hydrogen analysis scheme provides internationally recognized support for low-concentration hydrogen detection and real-time online compensation for CO, CO2, CH4, and O2 interference.
• The battery combustion heat flux module includes Hukseflux heat flux meters in 5 kW, 10 kW, and 20 kW ranges.
• The built-in water tank and pump circulation system supports up to 16 heat flux meters simultaneously.
• A 16-channel 16-bit Advantech acquisition module monitors heat flux data in real time with 1 Hz frequency through RS485 MODBUS RTU communication.

• The standard control cabinet is equipped with a Dell computer and 19-inch LCD monitor.
• The system uses 16-bit high-precision data acquisition modules with system time recording accuracy of 0.1 s.
• The control system and acquisition system communicate through Modbus digital transmission for real-time monitoring and accurate recording.
• Labview software provides modular functions for parameter setting, analyzer calibration, optical calibration, heat release calibration, test information input, testing, data analysis, and report printing.
• All test parameters including O2, CO2, CO, H2, hydrocarbon concentration, ambient temperature and humidity, atmospheric pressure, flow, pressure, transmittance, temperature, and heat flux can be displayed and individually enlarged or reduced.
• Real-time calculations include heat release rate, smoke production rate, oxygen consumption, CO2 generation, CO generation, mass loss, radiant heat, wind speed, and total heat release.
• The system provides preview mode and large-graph mode for result analysis, and supports correction of original data and parameter settings for effect analysis.
• Optical system calibration uses one-touch five-level automatic calibration at 0%, 25%, 50%, 75%, and 100%, with automatic report generation in Excel or PDF format.

• The FTIR smoke toxicity analysis system is based on Gasmet FTIR and is suitable for online toxicity analysis during fire testing.
• Typical measured toxic components include H2O, CO2, CO, N2O, NO, NO2, SO2, HCl, HF, NH3, CH4, C2H6, C3H8, C2H4, and additional expandable gas components.
• The full FTIR sampling path is heated to 180 °C and can measure sample gas without pre-drying.
• Spectral range: 500 to 4500 cm-1; resolution: 1 cm-1; scanning speed: 10 spectra per second; path length: 2 m.
• The system uses Peltier-cooled MCT detector, SiC150K infrared source, and ZnSe beam splitter.
• Measurement accuracy is ±2% of full scale and T90 is less than 120 s.
• Gasmet FTIR system provides ModBus, ASCII, COMLI, and DDE digital outputs, as well as 4-20 mA analog outputs.
• The sample probe model PSP4000H operates at 180 °C with 800 W heating power and 2 um ceramic filter element.
• The original calibrated components include H2O, CO, NO, SO2, NH3, HCl, HF, HBr, CO2, NO2, N2O, CH4, C2H4, C2H6, C3H8, C6H14, HCN, CH2O, C3H6O, and C3H4O within the concentration ranges listed in the source content.

• The temperature acquisition system uses Beijing Advantech modules with 180 channels, 16-bit resolution, temperature range 0 to 1370 °C, and display precision 0.1 °C.
• The monitoring system includes four Hikvision cameras and one hard-disk recorder, with 8 MP cameras, 4K resolution, 2.8 mm focal length, infrared distance up to 50 m, and white-light distance up to 30 m.
• The movable fire wall uses black fire-resistant surface material, 16 ±1 mm gypsum board, and 19.05 ±1 mm plywood, with two walls provided for each smoke system.
• Control system power requirement: 100 to 230 V AC, 3 kVA.
• Fan power requirement: 380 V AC, 130 kVA.

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